Wire harness manufacturing machine

ABSTRACT

The present invention is an automated wire harness machine ( 40 ) capable of manufacturing a wire harness ( 42 ) unique in-part due to the automation process. The novel wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires ( 46 ). Each un-stripped end portion ( 180, 182 ) of each wire is preferably terminated to one of a series of electrical connectors ( 44 ) of the wire harness. Each connector has at least one wafer ( 52 ) which houses a plurality of terminals ( 54 ) preferably crimped and electrically terminated to the ends of the wires. The wire harness machine preferably utilizes a pallet ( 56 ) which holds all of the wafers of one wire harness. A conveyor ( 58 ) transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter ( 64 ) which inserts and locks the terminals within pre-assigned cavities ( 114 ) of the wafers. The next station is an automated wire loader ( 66 ) which measures, cuts and crimps the two ends of each wire into the respective terminals of the loaded wafer assembly. A third station, or ultrasonic welder ( 68 ), the galls an un-stripped non-ferrous core ( 270 ) of the crimped wire to the terminal. The pallet with the loaded wafers, crimped terminals, and terminated wires are then transported to a wire marker station ( 70 ) which marks each wire, preferably via a laser ( 328 ), for identification purposes.

RELATED PATENT APPLICATION

This is a continuation-in-part application of U.S. patent applicationSer. No. 10/205,245, filed Jul. 25, 2002, and U.S. patent applicationSer. No. 09/993,797, filed Nov. 24, 2001 now U.S. Pat. No 6,588,646.

TECHNICAL FIELD

The present invention relates to an electrical connector, and moreparticularly to electrical connectors utilized in a wire harnessproduced by an automated electrical wire harness manufacturing machine.

BACKGROUND OF THE INVENTION

Electrical wire harnesses for automotive and other applications areassembled primarily through the use of manual labor. Areas of productionwhich contribute toward an appreciable degree of manual interventioninclude: measuring and cutting predetermined wire lengths, stripping ofinsulation jackets from each end of the cut wire, crimping a terminal tothe insulation jacket near the stripped end of the wire, electricallyengaging the stripped end of the wire to the terminal, and inserting theterminal into a connector housing. Each manual intervention during themanufacturing process is time consuming and can contribute towardoperator error, high manufacturing costs and/or a degradation of theoverall quality of the wire harness.

Known methods to electrically engage multi-stranded conductors or coresof wires to terminals requires the removal of the insulation jacket atthe electrical engagement area to achieve reliable electricalconductivity. Unfortunately, and especially true for smaller gaugemulti-stranded wire, the stripping process can lead to conductor/coredamage thus prohibiting the use of more fragile smaller gauge wires inmany electrical applications. Consequently, the cost in copper forlarger gauge wire is expensive, the overall bulk of the wire harness islarge and weight of the wire harness is high. Moreover, coupled withlarge gauge wiring and bulky harnesses, the terminals and thuselectrical connector housings attached to the distal ends of the wireharness are subsequently larger than otherwise necessary.

Because wire harnesses often contain dozens, if not hundreds of wires,often having varying wire gauges and wire lengths routed to a pluralityof separate connectors, various means of identifying the wires and thuspreventing wrong terminations, or simply poor terminations have beenutilized. One such means is assigning a specific color or color patternof insulation jacket 178 to a specific gauge wire size. This techniquecan be limiting and cumbersome in the manufacturing environment of wireharnesses, because the wire must be identified prior to the terminationof the wire to the terminal and insertion of the terminal into theconnector housing. Moreover, the wires, terminals, and/or connectorterminal cavities must still be identified to assure proper terminationsand possibly assist in maintenance issues. Such identification hastypically been done with ink print on the outside of the wire which hasa tendency to wear off in a harsh environment.

SUMMARY OF THE INVENTION

The present invention is an automated wire harness manufacturing machinecapable of producing a wire harness which is unique in-part to theautomation process. The novel wire harness is generally a plurality ofbundled, preferably un-stripped insulated wires. Each un-stripped end ofeach wire is preferably engaged electrically to one of a series ofelectrical connectors of the wire harness. Each connector has a seriesof stacking wafers which house a plurality of terminals preferablycrimped and terminated electrically to the end portions of the insulatedwires.

The wire harness manufacturing machine preferably utilizes a palletwhich holds all of the wafers of one wire harness. A conveyor transportsthe pallet and wafers through a series of stations which perform aseries of automated sequential manufacturing steps. The first station isa terminal inserter which inserts and locks the terminals withinpre-assigned cavities of the wafers. The next station is an automatedwire loader which selects the gauge wire, feeds it, measures, cuts,places and crimps the two ends of each selected wire into the respectiveterminals of the loaded wafer assembly. A third station, or ultrasonicwelder, then galls the non-ferrous core of the crimped wire to theterminal. The pallet with the loaded wafers, crimped terminals, andterminated wires are then transported to a wire marker station whichmarks each wire, preferably via a laser, for identification purposes.

Two crimping devices of the wire loader station preferably crimp a pairof wings of the terminal about an insulation jacket of the respectiveend portions of each wire. The crimping devices preferably load thewire, having any one of a wide range of wire gauges, into respective andcommonly designed terminals via preestablished crimping distances ordownward movement dependent upon the gauge of wire selected andcontrolled via a controller. During the cutting and loading of eachwire, an elongated peak of each crimping device preferably imprints theun-stripped ends of each wire to assist the ultrasonic welding processto be performed at the next ultrasonic welder station.

The ultrasonic welder has a novel tip which contacts the top of theun-stripped and imprinted, wire end portion to be welded. A unique anvilof the welder projects upward toward the tip and through a window of thewafer to engage a bottom surface of the terminal pre-seated within thewafer. Because the ends of the wires are not stripped of theirinsulation jacket, a costly step of the traditional wire harnessmanufacturing process is eliminated. In addition, the traditional methodof stripping stranded wire cores or conductors of their insulationjacket would tear off some of the conductor strands degrading theelectrical connection. Smaller gauged wire with far fewer strandstypical can not afford strand damage, thus, larger gauged wire was oftenused to allow for strand damage during the stripping process. Becausethe wires are no longer stripped of the insulation jacket, the use ofsmaller gauged stranded wire, not otherwise available for particularapplication, is now possible. Moreover, traditionally the smaller crosssectioned wire lacked needed column strength for manual insertion of thewire or terminated lead into the connector. Whereas with the presentinvention, the terminals are pre-inserted into the connector. Use ofsmaller gauged wire saves in the cost of wire, and reduces the overallweight and bulk of the wire harness.

During the welding process, the downward movement of the tip of theultrasonic welder compresses the wire ends against the terminal causinga tendency for the wire to move laterally with respect to the terminaland away from the desired weld location. The anvil or the tip of thewelder preferably has a pair of ears which project upward beyond and oneither side of the terminal to prevent this lateral wire movement andthus trap the wire end at the weld location. This trapping technique andthe ability to ultrasonic weld the end portion of an un-stripped wireenables the electrical engagement of a series of small gauged wires to asingle terminal, not previously achievable. Likewise, the ears will trapthe conductor strands of a larger diameter wire, in effect, enabling thewelding of a greater range of wire gauges not previously achievable.

The terminals are preferably of a tuning-fork design preferably having agreater thickness at a tuning fork portion end than at an opposite wirecrimping portion end of the terminal. The difference in terminalthickness provides mating strength and reliability to the mating end ofthe terminal while maximizing the volume defined by the crimp portion ofthe terminal for receipt of larger gauge or multiple wires. That is, thecrimping portion of the terminal is able to handle a larger wirediameter (or greater range of wire gauges) and is also able to handle agreater number of wires for multiple wire connections to one terminal.The overall effect is a compact electrical connector design whichminimizes the overall size and weight of the electrical connector of thewire harness.

Because the terminals are inserted into the wafer before they areengaged electrically to the wire, a series of novel locking features ofthe wafer to the terminal not only hold the terminal in place whenreceiving the mating connector pins, but also hold the terminals inplace to undergo the remainder of the manufacturing processes,previously described. During final assembly of the connector, the wafersare stacked to one another and indexed via lateral ribs which snugly fitinto a linear clearance of the next adjacent wafer. The ribs also indexthe wafer to the pallet during the manufacturing process and help tostiffen or provide a locking feature of the wafer to the terminal whichadds to the reliability of the mating and un-mating of the electricalconnector.

Advantages of the present invention include a highly versatile waferwhich can be utilized, amongst other application, within a connector ofa wire harness. Another advantage of the present application is aterminal which provides a compact design when utilized with the waferyet accepts large gauge wires. Yet, other advantages of the presentinvention is a wire harness manufacturing process which produces aninexpensive, compact, and highly reliable and maintainable wire harnesswith minimal manual labor.

BRIEF DESCRIPTION OF THE DRAWINGS

The presently preferred embodiments of the invention are disclosed inthe following description and in the accompanied drawings, wherein:

FIG. 1 is a top view of a wire harness manufacturing machine of thepresent invention;

FIG. 2 is a perspective view of a wire harness of the present inventionproduced by the manufacturing machine;

FIG. 3 is an exploded perspective view of an electrical connector of thewire harness;

FIG. 4 is a perspective view of a pallet of the manufacturing machine;

FIG. 5 is a perspective view of a wafer of the electrical connector;

FIG. 6 is a top view of the wafer;

FIG. 7 is a bottom view of the wafer;

FIG. 8 is a side view of the wafer;

FIG. 9 is a blade receiving end view of the wafer;

FIG. 10 is a lateral cross section of the pallet illustrating a lid ofthe pallet shown in an open position;

FIG. 11 is a lateral cross section of the pallet illustrating the lidshown in a closed position;

FIG. 12 is a front view of a terminal inserter station of the wireharness manufacturing machine;

FIG. 13 is a side view of the terminal inserter station;

FIG. 14 is an enlarged side view of the terminal inserter station takenfrom FIG. 13;

FIG. 15 is a top view of the terminal inserter station;

FIG. 15A is a cross section of a head of the terminal inserter station;

FIG. 16 is a perspective view of a terminal of the electrical connector;

FIG. 17 is a perspective view of a wafer assembly of the electricalconnector with portions cut-away to show internal detail;

FIG. 18 is a perspective view of two wafer assemblies of the electricalconnector shown stacked together and with portions removed to showinternal detail;

FIG. 19 is a perspective front view of a wire loader station of the wireharness manufacturing machine;

FIG. 20 is a fragmented perspective view of a frame, crimp device andhousing of the wire loader station;

FIG. 21 is an enlarged perspective view of a distal end of a wire of theelectrical connector;

FIG. 22 is an enlarged bottom perspective view of the crimp device ofthe wire loader station;

FIG. 23 a side view of the wire loader station;

FIG. 24 is a front view of the wire loader station;

FIG. 25 is a front view of the crimp device show engaged to the wire;

FIG. 26 is a side view of the crimp device;

FIG. 27 is a top view of the crimp device with portions cut-away to showinternal detail;

FIG. 28 is a perspective view of an ultrasonic welder station of thewire harness manufacturing machine;

FIG. 29 is a front view of a sub-controller of the ultrasonic welderstation;

FIG. 30A is a side view of a tip prop of the ultrasonic welder stationorientated over the wafer assembly held within the pallet of the wireharness manufacturing machine;

FIG. 30B is a side view of the tip prop orientated over a weld segmentof the end portion of the wire with the terminal crimped to the endportion and the wafer and pallet removed to show detail;

FIG. 30C is a side view of the tip prop orientated over and pressinginto an insulation jacket of the weld segment of the wire to form a weldand with the pallet and portions of the wafer removed to show internaldetail;

FIG. 30D is an enlarged lateral cross section of a tip, and an anvil ofthe ultrasonic welder station bearing down upon two wires and with theterminal seated within the surrounding wafer;

FIG. 31 is a top view of the wafer assembly illustrating a series ofwires welded to the terminals;

FIG. 32A is a front view of the tip prop of the ultrasonic welderstation;

FIG. 32B is a side view of the tip prop of the ultrasonic welderstation;

FIG. 33A is a top view of the anvil;

FIG. 33B is a front view of an anvil prop of the ultrasonic welder;

FIG. 33C is a side view of an anvil prop;

FIG. 34 is a side view of a wire marker station;

FIG. 35 is a front view of the wire marker station;

FIG. 36 is a perspective view of the pallet aligned to a tray of thewire marker station; and

FIG. 37 is an exploded perspective view of a comb device of the wiremarker.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1–3, an automated wire harness manufacturing machine40 of the present invention produces a novel wire harness 42, as bestillustrated in FIG. 2. The wire harness 42 has a plurality of connectors44 which are interconnected electrically to one another by a series ofbundled electrically insulated wires 46. Each connector 44 has pluralityof wafer assemblies 48 which are stacked and indexed to one-anotherwithin a connector housing 50. An electrical insulating wafer 52 of eachwafer assembly 48 houses and locks to a plurality of terminals 54 whichare spaced apart and aligned side-by-side to one another via the wafer.The wafers 52 have electrically insulating properties and are preferablymade of injection molded plastic. Generally, one end of at least oneinsulated wire 46 is terminated to a respective terminal 54 of the waferassembly 48 of a particular connector 44, and the other end of the samewire is engaged to another wafer assembly of a different connector 44thereby linking the connectors together, hence a mounting to the wireharness 42.

Alternatively, the terminals 54 of a single wafer 52 can beinterconnected electrically by a modified terminal or a wire looped backto terminals within the same wafer 52, thereby, functioning as a type ofbus bar. Referring to FIGS. 1 and 4, the harness manufacturing machine40 manufactures each wire harness 42 from the platform of a pallet ortray 56 which is indexed and moves along a transporter or conveyor 58.Preferably, all of the wafer assemblies 48 of any one wire harness 42are carried via a single pallet 56 through the manufacturing process.Indexing movement of the conveyor 56 is accurate enough to align eachterminal 54 of the wafer assembly 48 adjacent to each station of themanufacturing machine 40 which performs a specific function within theoverall process.

The stations shown in FIG. 1 and in consecutive order along the conveyor58 include; a pallet station 60 for mounting the pallet 56 when emptyonto the conveyor 58, a wafer load station 62 for manually loading theempty wafers 52 into the pallet 56, a terminal inserter 64 for theautomated insertion of the terminals 54 into the wafers 52, a wireloader 66 for the automated feed, measure, cut, placement and crimpingof the wires 46 to the terminals 54 an ultrasonic welder 68 for theautomated welding of the ends of the wires 46 to the respectiveterminals 54, a laser marker 70 for the automated marking of the wireinsulation jacket thus identifying each wire 46, a harness station 72for unloading the wafer assemblies 48 and terminated wires 46 from thepallet 56, and a second pallet station 74 for removing the pallet fromthe conveyor 58 and returning the empty pallets to the first palletstation 60. The various stations 64, 66, 68, 70 and advancement of theconveyor 58 are controlled automatically via a controller 75. As analternative design, the pallet 56 may also be an integral part of thetransporter or conveyor 58 which would eliminate the need for the firstand second pallet stations 60, 74.

The Pallet and Pallet Loading Station:

Referring to FIG. 4, the pallet 56 is elongated along the conveyor 58which moves in the direction of arrow 77. The pallet 56 and is largeenough to receive all of the wafers 52 for at least one wire harness 42.The wafers are orientated side-by-side in a planar arrangement withinthe pallet 56 at the wafer load station 62 so that the terminals 54 whenlater inserted into the respective wafer 52 at the terminal inserter 64,are positioned substantially perpendicular to the longitude of thepallet 56.

Referring to FIGS. 4–9, when the wafers 52 are manually loaded onto thepallet 56, a bottom face 82 of the wafer 52 is in direct contact with atop surface 80 carried by a main body 76 of the pallet 56. Toaccommodate access for sonic welding of the terminal 54 to the wire 46(discussed later in detail), a portion of the wafer 52 overhangs alongitudinal front surface 78 of the body 76 which is disposedsubstantially perpendicular to the top surface 80. A top face 84 of thewafer 52 is disposed opposite the bottom face 82 and both faces spanlaterally between a first and an opposite second side face 86, 88, andspan longitudinally between a connector or blade receiving end face 90and an opposite wire end face 92 of the wafer 52. The wafer 52 isgenerally divided between a leading portion 94 which carries thereceiving end face 90, and a trailing portion 96 which carries the wireend face 92. It is the trailing portion 96 which substantially overhangsthe body 76 of the pallet 56. Further description of the wafer 52 isprovided in parent U.S. Pat. No.6,837,751 (co-pending application Ser.No. 10/205,245), incorporated herein by reference. Moreover, furtherdescription of the wafer 52 and how it relates to the wafer assembly 48,and how the wafer assembly 48 relates to the connector 44 as a wholewill be described later within this specification.

The wafer 52 must be loaded into the pallet 56 from a substantiallyvertical direction, as indicated by arrow 99 of FIG. 4, so that amultifunctional rib 100 of the wafer 52 is able to fit snugly into anindexing groove 98 defined by the top surface 80 of the pallet 56. Thebottom surface 82 at the leading portion 94 of the wafer 52 restsdirectly against the top surface 80 of the pallet 56. The groove 98extends longitudinally with respect to the pallet 56, and the rib 100extends laterally with respect to the wafer 56 between the first andsecond side faces 86, 88 and projects downward from the bottom face 82at the trailing portion 96 and substantially near the leading portion 94of the wafer 52.

Referring to FIGS. 4, and 10–11, the pallet 56 has a series of lids orcaps 102, one lid for each respective wafer 52, which serve a dualfunction; the first being to space the first side face 86 of one waferaway from the second side face 88 of the next adjacent wafer 52, and thesecond function is to prevent the wafers 52 from lifting upward out ofthe indexing groove 98 during the automated manufacturing process. Thelids 102 are constructed and arranged to slide substantiallyhorizontally and laterally with respect to the elongated body 76 of thepallet 56 from an open position 104 to a closed position 106 wherein thewafers 52 are secured or locked in place.

When the wafers 52 are loaded into the pallet 56 at the wafer loadstation 62, all of the lids 102 are initially in the open position 104.The first wafer 52 to be loaded into the pallet 56 is located at theleading end of the pallet 56 with respect to the forward moving conveyor58. The second side face 88 of the first loaded wafer 52 is buttedagainst a stop or upward projecting pin (not shown) of the pallet body76 which aligns the wafer 52 longitudinally with respect to the pallet56 and thus prevents the wafer 52 from moving in a forward directionwith respect to the conveyor 58 movement. The respective lid 102 is thenslid horizontally to the closed position 106 preventing the wafer 52from lifting upward out of the laterally indexing groove 98 of thepallet 56.

Each lid 102 of the pallet 56 has a substantially planar and horizontalcover plate 108 which prevents the upward movement of the wafer 52 outof the groove 98, and an elongated shoulder or lip 110 which separatesthe wafer 52 from the next adjacent wafer. The lip 110 projects downwardfrom an edge of the plate 108 which is generally disposed away oropposite from the leading end of the pallet 56, and co-extendslongitudinally with the direction or axis of movement 101 of the lid102. After the first wafer 52 is loaded into the pallet 56 and therespective lid 102 is moved to the closed position 106, the lip 110prevents the first wafer 52 from moving longitudinally along the pallet56 and away from the forward stop. When the second or adjacent wafer 52is loaded into the pallet 56, the same lip 110 of the adjacent closedlid 102 acts as the stop which prevents the second wafer 52 from beingplaced to far forward within the pallet 56. The second lid 102 is thenclosed and the process of loading additional wafers within the palletrepeats itself. During this loading process, all of the wafers 52 areempty or void of terminals 54.

Referring to FIG. 36, the pallet 56 includes an optional steel toolinsert 111 illustrated at the end of the pallet to hold individualterminals 54 which are not seated within a wafer 52 but do requiretermination to a wire 46 of the wire harness 42. This is advantageouswhen using a single lead that is not carried by the connector 44 andinstead mates directly to an adjacent electrical system.

It is currently anticipated that because of the varying structure ofwafers 56 which could be placed into the pallet (i.e. varying number ofterminal cavities), manual selection and placement into the pallet ismore cost effective than automating it. However, if cost and efficiencyare ever proven otherwise, automating the loading of the pallet 56 withthe wafers 52 could be accomplished. Regardless, the pallet 56 isconfigured in anticipation of the components or wafers that are going inand thus the configuration would assure the proper wafer is loaded intothe proper location of the pallet. The pre-configuration is necessary tostop axial or longitudinal slide of the wafer 52 with respect to thepallet 56. Even when the lid is closed and has engaged the wafer in afairly firm interference fit, smaller wafers could still slide axiallyif the pallet is not reconfigured. The lid 102 of the pallet 56 dictatesthe size and placement of the wafers 52 in the pallet 56. The lids 102are constructed and arranged to be disassembled from the body 76 of thepallet and replaced with lids of different sizes to handle differentsize or width wafers.

The Terminal Inserter:

Referring to FIGS. 12–16, with all the necessary wafers 52 loaded intothe pallet 56, the conveyor 58 moves the loaded pallet 56 forward to theterminal inserter or inserter station 64. The terminal inserter cutseach preformed terminal 54 from a coiled carrier strip 112 and insertseach terminal 54, along a substantially horizontal imaginary plane, intoeach required terminal slot or elongated cavity 114 defined by the wafer52. A vertical moving head 116 of the terminal inserter 64 positions,holds, and shears the terminals 54 individually away from the carrierstrip 112. The linear motion of the head 116 is derived or translatedfrom rotational motion of a servo motor 118 via a gearbox 120. Once cut,a rigid pusher 122 of the inserter 64 pushes the terminal into theterminal cavity 114 of the wafer 52. The pusher 122 moves via apneumatic cylinder or servo motor 124 which delivers sufficient force sothat the terminals 54 lock within their respective cavities 114. Thenovel features of the terminals and how the terminals lock into thewafer 52 are described in-part in parent U.S. Pat. No. 6,588,646(co-pending U.S. patent application Ser. No. 09/993,797), incorporatedherein by reference, and will be further described later within thisspecification.

Referring to FIGS. 12 and 16, the elongated terminals 54 are engaged toone another via the terminal strip 112, or more specifically, via aseries of strip blanks or slugs 125 engaged unitarily to and interposedby the base portions 126 of the terminals 54. When the terminals 54 arecontained within the coiled form, each base portion 126 has a firstlongitudinal edge 128 engaged to one strip blank and a substantiallyparallel and opposite second longitudinal edge 130 engaged unitarily tothe next strip blank. Or, in other words, each respective strip blank125, prior to being cut away by the terminal inserter 64, is engagedcontiguously between the first edge 128 of a terminal 54 and the secondedge 130 of the next adjacent terminal 54.

Extending longitudinally outward from one end of the elongated baseportion 126 is a crimping portion 132 of the terminal 54. The crimpingportion has a pair of crimp wings 133 disposed generally perpendicularto the base portion 126 and extending upward when the terminal 54 is inthe pre-formed and un-crimped state. One wing 133 projects generallyupward from the first edge 128 and the other wing 132 projects upwardfrom the second edge 130. The wings 133 are offset from one anotherlongitudinally along the terminal.

The opposite end of the base portion 126 is essentially a rigid supportflap 134 which is substantially co-planar to the remainder of the baseportion. A receptacle or tuning-fork portion 136 of the terminal 54projects generally longitudinally outward from the flap 134. Althoughthe fork portion 136 is substantially aligned parallel to the baseportion 126, the fork portion 136 substantially lies within an imaginaryvertical plane and projects laterally upward from the second edge 130 atthe flap 134 of the base portion 126 and to an uppermost top edge 138 ofthe fork portion 136. A substantially vertical elongated plate 140 ofthe tuning-fork portion 136 extends longitudinally with respect to theterminal 54 and is engaged unitarily between the second edge 130 at theflap 134 and a pair of elongated substantially parallel prongs 142. Thespace directly between the prongs 142 defines a slot or receptacle 144which receives the electrically conductive pin or blade of a matingconnector (not shown). The uppermost prong 142 carries the uppermost topedge 138 of the terminal 54.

Referring back to the terminal inserter 64; when in operation, theconveyor 58, via the controller 75, moves the loaded pallet 56 andwafers 52 to the terminal inserter 64. The controller 75 signals whichcavity 114 of which wafer is to receive a terminal 54 and the respectivecavity 114 is thus placed in front of the plunger 122 for receiving theterminal 54. During this time, the head 116 is performing a singlecycle, wherein the coiled carrier strip 112 is advanced one terminal 54and one carrier strip slug 125 via a pronged indexing wheel 143 whichrotates via a servo motor. As previously described, each blank 125 isengaged laterally between adjacent terminals 54. A terminal guide bar135 swings downward via a precision actuator or servo motor 137 toengage and maintain the vertical orientation of the distal terminal 54of the coiled carrier strip 112. The head 116 moves downwardhorizontally positioning the carrier strip 112 with a downwardprojecting pilot pin 139 which extends through a pilot hole of the slug125. In the same downward movement of the head 116, the carrier strip112 is held downward via a spring loaded pressure pad 141 which directlyengages the slug 125. As a final step of the downward movement of thehead 116, a downward projecting punch 14. As a final step of thedownward movement of the head 116, a downward projecting punch 147 ofthe head 116 shears off the slug 125 from the adjacent terminal andpushes the slug through a shear hole or die (not shown) of the terminalinserter. By shearing the slug 125 away from the base portion 126 of theadjacent terminals 54, the first and second edges 128, 130 of theterminal base portions 126 are formed.

The terminal 54 at the free end of the coiled carrier strip 112 is thusfreed it is positioned in front of the horizontal plunger 122. The head116 then moves upward back to its initial position as the plunger 122engages the crimping portion 132 of the terminal 54 and inserts theterminal into the wafer 52. By way of the controller 75, the conveyor 58indexes forward to the next wafer cavity 114 designated to receive aterminal 54 while the coiled carrier strip 112 simultaneously advancesfor the next terminal cutting, and hence the cycle repeats itself.

Although not shown, the terminal inserter 64 may include an automaticdetect mechanism which could detect which lid location of the pallet 56actually has a wafer 52 mounted therein. That is, if along the pallet56, a wafer 52 is not inserted, the terminal inserter 64 will skip thatwafer location of the pallet 56 and move on to the next. This can bedone with machine vision technology, or could be done with an insertionforce detector so that when the inserter 64 thinks its inserting, if itdoes not experience any resistive forces otherwise produced by lockingfeatures of the absent wafer it will not insert the terminal at thatlocation.

Because the height of the terminal 54 is slightly less than the depth ofthe terminal cavity 114, the lid 102 of the pallet 56 snugly engages thewafer 52 but is spaced slightly above the top edge 138 of thetuning-fork portion 136 of the terminal 54. Therefore, attributes of thewafer 52, and not the lid itself, are relied upon to hold the terminal54 vertically within the wafer 52 as the pallet 56 progresses throughthe manufacturing process. Because of this clearance, the terminal 54does not engage or experience frictional resistance from the lid 102during the terminal insertion process. If it were to experience suchresistance, the lid could potentially move to the open position 104 thusreleasing the wafer or causing damage to the terminal 54 itself.

Referring to FIGS. 5–9 and 18–19, the elongated terminal cavities 114 ofeach wafer 52 are separated by a wall 146. Each cavity 114 is defined bya first side 148 of a wall, a second side 150 of the next adjacent wall146 and a cavity floor 152 which spans laterally between the first andsecond sides 148, 150. Each cavity has a furrow 154 which terminates atthe receiving end face 90 of the wafer 52, and a communicating vestibule156 which terminates at the end face 92 of the wafer 52. The furrow 154snugly holds the generally vertical tuning-fork portion 136 of theterminal 54 and the vestibule 156 holds the generally horizontal baseand crimping portions 126, 132 of the terminal 54, therefore, the furrow154 is appreciably narrower than the vestibule 156.

The multiple locking attributes between the wafer 52 and each terminal54 includes a longitudinal or horizontal lock feature 158 and a lateralor vertical lock feature 160 which engage mating features of theterminal when the terminal 54 is initially inserted into the wafer 52via the terminal inserter 64. The longitudinal lock feature 158 preventsthe terminal 54 from backing out of the wafer 52 after insertion, andthe lateral lock feature 160 prevents the terminal 52 from liftingupward and out of the vestibule 156 of the cavity 114.

The longitudinal lock feature 158 has a resilient arm 162 which projectsunitarily outward from the first side 148 substantially between thefurrow 154 and the vestibule 156 of the cavity 114. The arm 162 projectsat an angle longitudinally into the furrow 154 and laterally across ittoward the second side 150. During insertion of the terminal 54 into thewafer 52, the prongs 142 of the of the tuning fork portion 136 of theterminal 54 engages a ramped or enlarged distal head 164 of the arm 162causing the head 164 and arm 162 to flex toward the fist side 148. Thehead 164 slides directly against the longitudinal side of the prongs 142and against the plate 140 of the terminal 54 until the head resilientlysnaps into a notch 166 carried by the plate 140 and which communicatesthrough the top edge 138 of the fork portion 136 of the terminal 52, asbest shown in FIG. 19. The arm 162 and the head 164 are spaced slightlyabove the cavity floor 152 so that the rigid flap 134 of the baseportion 126 of the terminal 54 can slide in-part beneath the arm 162.

Referring to FIGS. 18–19, the head 164 has a forward stop face 168 whichengages a rearward edge surface 170 which in-part defines the notch 166to prevent the terminal from backing out of the cavity 114. The terminal54 is prevented from moving or inserting too far into the cavity 115 viacontact between tips 172 of each prong 142 and a shelf 174 carried bythe wafer 52 at the receiving end face 90. The shelf 174 also defines abeveled blade or pin aperture 175 carried by the receiving end face 90of the wafer 52 which communicates with the furrow 154, as best shown inFIG. 9, and receives the pin of the mating connector, not shown.

Referring to FIGS. 6 and 18, the lateral lock feature 160 has a ledge176 which projects unitarily outward from the first side 148 and intothe vestibule 152 of the cavity 114 and near the furrow 154. Both theledge 176 and the resilient arm 162 are elevated upward, or spaced, fromthe cavity floor 152. For additional rigidity, the ledge 176 alsoprojects laterally and unitarily outward and rearward from the arm 162.The ledge 176 is disposed substantially parallel to the cavity floor152, so that insertion of the terminal 54 into the cavity 114 causes therigid flap 134 of the base portion 126 of the terminal 54 to slidesnugly under the ledge 176. In other words, because the spacing betweenthe ledge 176 and the cavity floor 152 is substantially equal to thethickness of the base portion 126 of the terminal, the terminal isprevented from lifting upward out of the vestibule 152.

In operation, with the terminals 54 locked within the pre-designatedcavities 114 of the wafers 52, the pallet 56 advances to the nextprocess via the conveyor 58 and controller 75.

The Wire Loader:

Referring to FIGS. 1 and 19–27, the next stage is the wire loader orloader station 66 which is constructed and arranged to draw wire 46under a constant tension from a plurality of drums or dispensers 176.The wire loader 66 measures each wire to a predetermined length, cutsthe wire, places it, longitudinally perforates an insulation jacket 178at each end of the wire to assist sonic welding, and crimps each end ofthe wire 46 to a respective terminal 54. The flexibility of the wireloader 66 can deliver up to twelve different cables or wires with fouror more different gauge sizes ranging from 0.13 square millimeters to0.80 square millimeters and having solid or stranded conductive cores.The wire loader 66 feeds the wires 46 out to a pre-established lengthbased on program software within the controller 75. It cuts and placesthe wire 46 in a predetermined assigned vestibule 156 of the terminalcavity 114 of the wafer assembly 48. These are the same cavities 114where the terminals 54 have been previously placed, so the wires 46 areactually inserted only into the wafer cavities 114 that have a terminal54. This is to be distinguished with conventional practices whichtypically place a terminal in every cavity of the electrical connector,whether ultimately used or not. The automated capability of the presentprocess avoids the need to load terminals 54 into cavities 114 wherethey are not needed for the final wire harness 42.

Referring to FIGS. 20 and 21, each length of wire 46 has a distal endportion 180 and a cut end portion 182. Each of the end portions 180, 182have a crimp segment 184 which extends longitudinally to a projectingdistal weld segment 186. The weld segment 186 carries a traversingcut-off surface 188 wherein the electrically conductive core of the wire46 is exposed and disposed substantially concentrically and radiallyinward from the insulating jacket 178.

Referring to FIG. 23, a cable track mechanism 189 is constructed andarranged to stage up to twelve wires and can move the wires fromside-to-side relative to a stationary frame 192 of the loader 66aligning each wire for feeding when required.

The wire 46 feeds through a single port 190 carried by the stationaryframe 192 of the loader 66 and is guided within a semi-circular concavesurface of a housing or basket 194 looping the wire around until thecutoff surface 188 of the distal end portion 180 of the wire 46 buttsagainst a substantially vertical planar indexing surface or block 196engaged rigidly to the frame 192. The indexing surface 196 co-extendslongitudinally with the conveyor 58 and also serves as a cutting surfaceor cutting block for the cut-off end portion 182 of the wire 46.Consequently, the indexing surface 196 of the loader 66 simultaneouslyaligns the cut-off surfaces 188 for both end portions 180, 182vertically above and longitudinally to the base portion 126 of theterminal 54 within the vestibule 156 of the wafer cavity 114. At thispoint, the crimp segment 184 of the wire end portion 182 is alignedlongitudinally and vertically above the crimping portion 132 of therespective terminal 54 and the weld segment 186 is alignedlongitudinally and vertically above the base portion 126 of the sameterminal 54.

The opposite end portion 180 of the wire 46 which was looped back andhas butted against the indexing surface 196 is aligned longitudinally tothe terminals held within the pallet 56 but is not yet directly abovethe terminal 54 to which it will be crimped. It is only after the crimpsegment 184 of the end portion 182 is crimped that the conveyor 58 willmove in a forward or reverse direction, via the controller 75, to alignthe respective terminal 54 directly under the end portion 180, at whichpoint the end portion 180 is lowered and crimped to the second terminal.

With respect to the wafer 52, the cut-off surfaces 188 of the wire endportions 180, 182 are aligned vertically and disposed slightlyhorizontally or longitudinally away from the ledge 174 of the laterallock feature 160, via the cutting block 196. This is necessary toprevent the insulation jacket 178 of the wire 46 from flowing into theledge 174 are during the weld process which could interfer with thestacking of the wafers during final assembly of the connector 44.

In operation, the distal end portion 180 embarks upon the concave guidesurface of the horse-shoe housing 194 as the wire 46 feeds through theport 190. Once the cut-off surface 188 of the distal end portion 180 ofthe wire 46 contacts the indexing surface 196 of the cutting block, theotherwise obstructing horse-shoe housing 194 is moved mechanicallyupward, permitting any remaining length of wire to be fed through theport 190. A vertical moving crimp device 202 then grips the cut-off endportion 182, and a second vertical moving crimp device 204simultaneously grips the distal end portion 180 of the same wire 46.Preferably, the conveyor 58 pre-aligns the terminal 54 under the firstcrimp device 202 in preparation for loading the cut-off end portion 182of the wire 46 before the cycle of the wire loader 66 begins. Oncegripped, the cut-off end portion 182 is loaded into the terminal andcrimped by the crimp device 202.

After the cut-off end portion 182 is loaded and crimped, the conveyor 58either advances or reverses to align the second crimp device 204 to thesecond terminal 54 for loading and crimping of the distal end portion180 of the wire. It should be apparent that which ever end portion 180,182 is aligned to the respective terminal 54 first, and thus crimpedfirst, can be easily reversed. Moreover, as a design alternative, thesecond crimp device 204 can be constructed and arranged to move alongthe stationary conveyor 58 instead. That is, the conveyor need not moveprior to loading of the second or distal end portion 180 of the wire 46,instead, the second crimp device 204 can move to the terminal to becrimped. However, for the sake of design simplicity and cost, backwardor forward movement of the conveyor 58, as illustrated in FIG. 19, isthe preferred alternative.

Both crimp devices 202, 204 are substantially identical but operateindependently from one another and in coordination with the conveyor 58.Each device 202, 204 has a pair of opposing and pivoting grippers 206each having inward faces 208 constructed and arranged to pivot inwardtoward one-another to laterally engage the respective end portions 180,182 of the wire 46. Each gripper has a ball-spring-pin arrangement (notshown) to bias the grippers in a closed position or against the wire.

Referring to FIGS. 19 and 25–27, once both ends 180, 182 are gripped, orsimultaneously thereto, the conveyor 58 moves the pallet 56 in a forwardor reverse direction so that a pre-determined terminal 54 is alignedunder the distal end portion 180 of the wire 46. A vertical moving rodor plunger 210 of the crimp device 202 moves downward and is guidedwithin opposing vertical channels 212 carried by the inward faces 208 ofthe grippers 206 engaged pivotally to the frame 192. A distal,multi-functional contact face 214 of the plunger 210 makes directcontact with the insulation jacket 178 at the weld and crimp segments186, 184 of the end portion 180. The face 214 engages the jacket 178 andmoves the end portion 180 of the wire 46 downward, thus sliding the wire46 against the inward faces 208 of the grippers 206 disposed immediatelyabove the vestibule 156 of the wafer cavity 114. Continued downwardmovement of the plunger 210 releases the wire 46 from the grippers 206and places the end portion 180 directly into the terminal 54. Furtherdownward movement causes a concave crimp quadrant 215 of the contactface 214 to engage the crimp wings 133 of the terminal 54, bending thewings toward one another and firmly about the insulation jacket 178 atthe crimp segment 184 of the wire 46.

Referring to FIGS. 22 and 25–27, the plunger 210 has a generallyT-shaped cross section formed by a four-sided elongated mid-section 216and a first, second, third, and fourth leg 218, 220, 222, 224 extendingcontiguously in four respective directions from each side of themid-section. The first and second legs 218, 220 project in oppositedirections from the mid-section 216 and into respective channels 212 ofthe grippers 206 to guide the plunger vertically. The channels 212 arepreferably deeper than the projecting distance of the first and secondlegs 218, 220 enabling the grippers 206 to collapse fully inward to gripthe smaller gauge wires 46. The third and fourth legs 222, 224 projectfrom one another in opposite directions from the mid-section 216 and aredisposed substantially perpendicular to the first and second legs 218,220. Both the third and fourth legs 222, 224 lie within an imaginaryplane disposed substantially perpendicular to the imaginary plane of thefirst and second legs 218, 220 and are generally parallel to thelongitude of the wire 46 at the end portions 180, 182.

The fourth leg 224 projects from the mid-section 216 to a verticalcutting edge 225. The cutting edge 225 is aligned above and very near tothe indexing surface or cutter block 196. Cutting of the wire 46 isaccomplish via a scissors effect wherein the cutting edge 225 of theplunger 210 passes very close to the cutting block 196 during itsdownward movement, thereby tearing the wire. The projecting length ofthe fourth leg 224 is generally equal to the length of the weld segment186 of the end portions 180, 182.

An imprint portion 226 of the contact face 214 which is carried by theend of the fourth leg 224 has a longitudinal rib or elongated peak 228designed to create an imprint or split 229 into the jacket 178 at theweld segment 186. Because it is preferable not to split the jacket 178through the cut-off face 188 of the end portions 180, 182, the elongatedpeak 228 does not extend all the way to the end or cutting edge 225 ofthe fourth leg 224. This prevents the jacket 178 from being cut throughto the cut-off face 188. Otherwise, during the welding process, meltingflow of the jacket 178 would be less controlled and could spill overinto undesirable areas of the terminal 54, such as the ledge 176 areawhich would hinder stacking of the wafer assemblies 48 during finalassembly of the connector 44.

The crimp quadrant 215 of the contact face 214 is disposed substantiallyperpendicular to the projection of the imprint portion 226, and iscarried by the ends of the mid section 216, the first leg 218 and thesecond leg 220. During crimping, each of the two upward projectingun-crimped wings 133 of the terminal 54 initially engage respective endsof the first and second legs 218, 220. The concave shape of the crimpquadrant 215 compel the wings 133 to bend inward toward one-another togrip the insulation jacket 178 at the crimp segment 184 of the wire 46.The distance the plunger 210 moves downward directly impacts the forceplaced upon the crimp segment 184 and dictated by the gauge of wire 46being crimped, known and controlled via the controller 75. The first andsecond legs 218, 220 need not extend the entire vertical length of theplunger 110, but do extend far enough to be reliably guided within thechannels 212 of the grippers 206 without binding.

Thus in a single stroke of the wire loader 66, there are four separateoperations. The first operation is measuring and dispensing a desiredlength of wire 46 for given wafer assemblies 48, the second is cuttingthe wire 46 between the cutting edge 225 of the plunger 210 and thecutting block 196, the third is placing the wire end portions 180, 182into the terminal base and crimping portions 126, 132, and the fourth iscrimping the terminal wings 133 via the crimp quadrant 215 of theplunger 210. Referring to FIGS. 19, 23 and 24, all four operations areaccomplished via a single stroke or cycle of a cam wheel mechanism 230which drives the plunger 210 of the crimp devices 202, 204. Rotation ofa wheel 232 of the wheel mechanism 230 causes a cam arm 234 connectedbetween the wheel 232 and the plunger 210 to generally pivot convertingthe rotational movement of the wheel to linear movement of the plunger.The degrees of rotation of the wheel 232 translates into the verticaldisplacement of the plunger 210. This displacement is automaticallyadjusted depending upon the gauge of wire being crimped. In any event,the wheel 232 rotates less than one hundred and eighty degrees via areversible electric motor 233 as best shown in FIG. 23.

To achieve a maximum range of wire gauges for a single waferapplication, the terminal 54 varies in gauge or thickness. That is, thecrimping portion 132 of the terminal 54 is considerable thinner than therest of the terminal. This thinner thickness of the crimping portion 132permits crimping of larger gauge wires 46 within the limited space ofthe terminal and/or wafer cavity 114. Likewise, the greater requiredthickness of the tuning-fork portion 136 of the terminal 54 provides thenecessary strength for reliable and repeatable mating of the electricalconnection. With the large volume within the crimping portion 132 andthe ability to finely adjust the vertical travel of the plunger 210,multiple wires 46 can be crimped to a single terminal 54. That is, thewire loader 66 essentially has variable press control giving theflexibility of having dynamic control over the crimp heights based onthe cable/wire size and number. Of course a less preferred design wouldbe to have a separate crimping device for each wire gauge size. In thisalternative design, the wheel 232 can simply do a complete revolution,or three hundred and sixty degree movement of the wheel 232, for eachstroke.

The Ultrasonic Welder:

Referring to FIGS. 1, 20 and 28–29, with a series of un-strippedinsulated wires 46 looped and crimped at each end portion 180, 182 torespective predetermined terminals 54 disposed within the pallet 56, thepallet moves via the conveyor 58 and controller 75 to the ultrasonicwelder or welder station 68. The ultrasonic welder 68 utilizesultrasonic energy to join non-ferrous metal of the terminal 54 to thenonferrous metal or conductor core 270 of the wire 46. It should beunderstood that ultrasonic welding is not conventional welding whereinmetals are heated and melted into each other, instead, mechanicalvibration is used to mutually gall the contact surfaces of the terminaland wire conductor core 270 together. This galling results incontaminants, such as surface oxidation, to be displaced along with theinsulation jacket 178 of the wire 46. The galling further causes thecontact surfaces to be polished. As galling continues, the contactsurfaces become intimate, whereupon atomic and molecular bonding occurstherebetween. The terminal 54 and the wire 46 are thereby bondedtogether with a weld-like efficacy.

Preferably, the welder 68 is an “Ultraweld 40” ultrasonic welder ofAMTECH (American Technology, Inc.) of Milford, Conn. This class ofcommercially available ultrasonic welders include: a solid state powersupply 250 which is user adjusted via the controller 75 whichcommunicates with an interposed microprocessor based sub-controller 252of the welder 68, a transducer where electrical energy of the powersupply is converted into mechanical vibration and an amplitude booster254 where the mechanical vibrations of the transducer are amplified, andan output tool in the form of a horn 256 which tunes the vibrations to anovel tip 258 specifically designed for the wire harness manufacturingmachine 40.

A number of factors collectively determine the efficacy of theultrasonic metal-to-metal surface bond, the major considerations beingthe amplitude of the vibration, the applied force and the time ofapplication. The applied power (P) is defined by the amplitude (X) ofvibration times the force (F) applied normal to the metal surfaces(P=FX), and the applied energy (E) is defined by the applied power (P)times the time (T) of application (E=PT). These variables arepredetermined to achieve the most efficacious bond based upon the metalsof the wire 46 and terminal 54.

Prior to operation of the ultrasonic welder 68, these operating values(i.e. amplitude, force and energy) must be entered into either thecontroller 75 or the welder sub-controller 252. The values arepre-established from empirical data previously taken which are furtherdependent upon many factors. These factors include but are not limitedto: wire or core gauge thickness, insulation jacket 178 thickness,terminal base portion 126 thickness, and types of materials. Otherparameters controlled or monitored via the sub-controller 252 includeenergy 253, force or trigger pressure 255 used during pre-heightmeasurement, pressure 257, amplitude 259, time 261, power 263,pre-height 265, and height 267.

The operator enters energy 253 as opposed to time 261 or height 267because empirical data has shown that better control of final productquality is achieved. Welding to height or time is less sensitive is lesssensitive to the condition of the terminal and cable. For instance, awire 46 with a missing strand welded to a given height does not providethe same weld quality as when all strands are present.

Trigger pressure 255 is used to compact the wire 46 on the terminal 54for the purpose of measuring the pre-height 265 before welding formonitoring purposes. If this height does not fit a pre-establishedheight range, a warning indication is provided wherein it is assumedthat the wrong sized wire is being used, the wire is missing, theterminal is mis-positioned, etc. The trigger pressure 255 should be setwithin about ten pounds per square inch of the final weld pressure 257.If the pre-height is within the pre-established range the welder 68 willbegin the weld process. For a typical weld, the process will take about0.5 seconds.

In regards to weld pressure 257, the actual pressure required to producea good weld when used in conjunction with energy 253 and amplitude 259.The pressure 257 that is set on the sub-controller 252 is applied to anair cylinder that will provide the clamping force of the horn's tip 258on the wire 46 and terminal 54 combination. Knowing the size of an aircylinder of the welder 68 which exerts force between the tip and thearea to be welded, and by calculation, a pounds per square inch force onthe actual welded area can be calculated.

The amplitude 259 is read in microns and moves generally coplanar to theterminal and wire. Electrical energy is applied to a converter 251 ofthe welder 68 where a crystal like material is excited at its naturalfrequency. A typical frequency is about forty kilohertz. The minutevibrations are transferred through the acoustically designed tunedbooster 254 and transferred along to the horn. The greater the voltageapplied to the converter, the greater the amplitude.

The welder 68 has a series of quality control features which monitor thewelding process. These monitoring features are generally adjustable,thus capable of controlling the number of rejected or non-conformingparts. The first monitoring feature is a time feature which monitors theactual time that ultrasonic energy is running. The feature time is notthe full cycle time but is the actual weld time. This time is a goodindication of the non-ferrous material quality and cleanliness. If theweld time exceeds a pre-established duration, it is a likely indicationthat contaminates exist. Oxides, or other contaminants are inherentlyslippery and do not allow the proper metal-to-metal friction necessaryto produce the weld.

A second quality control feature is that of power which is similar totime because work done on the weld is equal to power times time.Therefore, a weld that draws minimal power binds non-ferrous metals thatare more likely to contain higher levels of contaminants.

Aside from the pre-height feature previously discussed, a final heightquality control feature measures the final height of the weld. Undertypical welding scenario for a single wire, the variation in the finalheight should be about 0.1 millimeters. If the final weld height fallsabove this range, it is a warning indication of under welding mostlikely due to excess contamination. If the final weld height falls underthis range, it is a warning indication that wire strands have escaped orhave not been captured within the weld area and thus not included in theheight reading.

During operation of the welder 68, the weld segment 186 of the crimpedwire 46 and the base portion 126 of the terminal 54 are placed via theconveyor 58 directly between the tip 258 and a stationary anvil 260 ofthe welder 68. The tip 258 extends from above into the vestibule 156 ofthe wafer 52 and presses downward upon the insulating jacket 178 of thewire 46 at the weld segment 186. The anvil 260 of the welder 68 extendsupward through a weld window 262 of the trailing portion 96 of the wafer52 to directly contact a planar bottom surface or side 264 of the baseportion 126 of the terminal 54. The weld window extends through thebottom face 82 and the cavity floor 152 of the wafer 52 to communicatewith the vestibule 156 of the cavity 114.

In preparation for welding, the insulation jacket 178 at the weldsegment 186 of the wire 46 need not be stripped, but preferably has animprint or longitudinal slit 229, as previously described, to assist inthe welding process. Because of the unique design of the anvil 260 andthe tip 258 of the welder 68, the electrical conductor 270 of the wire46 is not limited to a solid core or single strand, but can be utilizedwith multi-stranded conductor cores or copper material. The insulatingjacket 178 which covers the conductor core 270 is of a meltable materialsuch as thermoplastic, and preferably polyvinyl chloride or polyester.The terminal 54 is nonferrous and preferably of a metal substantiallysofter than the steel of the tip 258 and anvil 260.

Referring to FIGS. 30A–D, during operation of the ultrasonic welder 68,the tip 258 moves downward relative to the stationary anvil 260 duringthe weld process. Both the tip and the anvil have mutually facing oropposing work surfaces 266, 268, but only the anvil work surface 268 isknurled to grip the bottom surface 264 of the terminal 54 as the tip isforced toward the anvil. The tip work surface 266 is smooth to reducethe time necessary to displace the insulation jacket 178. The frequencymay be fixed at twenty kHz, at forty kHz or at another frequency, or thefrequency may be other than fixed. In any event, the pre-establishedfrequency shall be such that a resonance frequency is not producedwithin the terminal 54 which could potentially damage or crack portionsof the terminal including the tuning-fork shaped prongs 142.

The work surface 266 of the tip 258 is initially moved into forcefulabutment with the insulation jacket 178 of the wire 46, wherein theinsulation jacketed wire is sandwiched against a top surface or side 277of the base portion 126 of the terminal 54. Simultaneously, the bottomsurface 264 of the base portion 126 is forcefully abutted against thework surface 268 of the anvil 260 by pivot plate 271 which pivots abouta pivot axis 273 disposed parallel to the conveyor 58. The pivot plate271 is actuated via a pneumatic cylinder (not shown) which moves thepallet 56 from a tilt up position 279 to a tilt down or anvil engageposition 275. As best shown in FIG. 30B, the pre-slit insulation jacket178 is further dimpled or deformed by the smooth work surface 266 of thetip 258, but not necessarily broken. At this stage of operation, themicroprocessor based controller 252 determines via a linear variabledisplacement transducer whether surfaces are located within apredetermined allowance, statistically pre-established. If not, an erroris called out, otherwise the microprocessor programming advances to thenext and final welding step.

If no error occurs, the solid state power supply 250 then activates thetransducer/booster 254, whereupon mechanical vibration arrives via thehorn 256 to the tip 258. The insulation jacket 178 thus vibrates withthe work surface 266 of the tip 258 relative to the wire 46. Withcontinued vibration, the insulation jacket 178 heats and melts, thusflowing away from the area directly between the work surface 266 of thetip 258 and the top surface 277 of the base portion 126 as the tipvibrates and continues to be forced toward the anvil 260, as best shownin FIGS. 30C and 31.

Referring to FIG. 31, upon conclusion of the ultrasonic welding process,the insulation jacket 178 has formed a displacement mass 269 ondiametrically opposing sides of an ultrasonic weld 272 where the tip 258was located. At the weld 272, a copper conductor 270 of the wire 46 isexposed at one side and bonded by the ultrasonic weld 272 to the topsurface 234 of the base portion 126 of the terminal 54. The vestibule156 of the cavity 114 of the wafer 52 must be large enough to displacethe mass 269 so that the melted insulating jacket does not flow intounwanted areas of the wafer cavity 114 which would disrupt the matingcapability of the connector 44 or hinder the stacking of the wafers 52to one-another. In-other-words, the displacement mass 269 must not flowor form appreciably forward of the initial cut-off surface 188 of thewire 46.

Referring to FIG. 30D, the ultrasonic welding process is capable ofwelding more than one wire 46 to a single terminal 54. As illustrated,two or more wires 46, preferably having ultra thin wall polyvinylchloride insulation jackets 178, can be ultrasonic welded to one-anotherand to the terminal 54. The wires 46 are preferably gathered togethervia a pair of ears 274 disposed substantially parallel to each other.Because the base portion 126 of the terminal 54 extends between the ears274, the ears are spaced apart from one another at a distance slightlygreater than the width of the base portion 126. To enable a multi-wireweld 272, the width of the tip 258 is almost as great as the distancebetween the two ears 274. The idea being, any distance between the tip258 and the ears 274 is smaller than the diameter of a single strand ofwire conductor 270. This assures every strand remains under the tip 258and thus exposed to the welding process. That is, all the strands ofcopper are captured under the welding tip and are not able to movelaterally away from the weld area.

As best illustrated in FIGS. 30A and 32A–B, an elongated linear prop 276is preferably unitary to the horn and carries two diametrically opposingtips 258 at respective ends. The unitary construction of the prop andhorn is preferred for consistent control of the energy and amplitudethrough the horn to the weld. As an alternative, the prop 276 can beengaged to the end of the horn 256 via a threaded nut 278 which engagesa threaded portion of the horn 256 that extends through a mid-point hole280 carried by the prop 276. The prop 276 is thus disposedconcentrically to the horn 256 and both as a single part are capable ofrotating one hundred and eighty degrees to utilize the second tip 258when the first tip 258 wears out or becomes damaged. Having two tips 258on each prop 276 reduces the cost of manufacturing the tip 258 andsimplifies maintenance of the ultrasonic welder 68. The tips 258 arepreferably made of a hardened steel which is coated with titaniumnitride for wear. Other hard coat materials such as chromium nitrite arealso acceptable. The tips are further void of any sharp edges whichcould damage or cut through the wire 46 prior to achieving an ultrasonicweld. As previously described, the tip work surface 266 is smooth andthus provides a quicker weld as opposed to neural patterns on the tip.Moreover, the smooth tip requires less machining to produce the tiptool. In order to ensure bonding of all the strands of the conductor 270of the wire 46, the tip work surface 266 must be substantially parallelto the top surface 234 of the base portion 126 of the terminal 54 (i.e.as oppose to a concave geometry). A parallel geometry provides a uniformpressure or force across the weld, thereby bonding all the strands.

Referring to FIGS. 33A–C, the anvil 260 is carried by an elongatedlinear anvil prop 282. Like the tips 258, preferably a pair of anvils260 are diametrically carried on respective ends of the anvil prop 282.Each anvil 260 supports the ears 274 as previously described. The ears274 are preferably constructed and arranged to be detachable from theanvils 260. With this configuration, in the event that one or both ofthe ears 274 should break, replacement or maintenance is limited to theears and not the whole anvil 260 and prop 282. The ears 274 are held tothe anvil 260 by a dowel or pin (not shown). The anvil 260 is made of ahardened steel for purposes of wear. Because the ears 274 are exposed tolateral forces or shear stresses, the ear material is not as brittle asthe anvil 260 material, and although hardened the ear steel is softerthan the anvil material. Moreover, the ears 274 are not exposed, andneed not withstand the wear, of the anvil 260, therefore, the ears 274need not be as hard.

The methodology according to the present invention has great utility forthe handling of small gauge wires 46, ranging at about twenty-six gauge.Small gauge wires are frequently very difficult to strip withoutinjuring the wire 46. This is especially true for wires 46 having astranded conductor or core 270. Consequently, ultrasonic welding ofsmall gauge wires 46 is costly and difficult. However, the methodaccording to the present invention does not require pre-stripping ofwires, so that now small diameter wires, including thin and ultra-thinwires ranging in insulator thickness from 0.4 to 0.2 millimeters, can beeconomically attached to the terminals 54.

A test which ensures a reliable ultrasonic weld 272 is referred to as asimple pull test, wherein the physical strength of the weld is actuallytested via the application of a mechanical force to see to if the bondbreaks. When applying the pull test, the terminal 54 is held at one endand the wire 46 is pulled from an opposite end. If the weld holds, thisconfirms that the weld is good and will conduct electricity becauseplastic will not secure a weld to the metal terminal, so if there issubstantial pull strength then you know that non-ferrous metal is weldedto non-ferrous metal.

Although not illustrated, it is possible to form all the ultrasonicwelds 272 across a single wafer at one time. However, each tip 258 foreach respective terminal 54 must be capable of detecting the height andpressure necessary for the individual wire 46. Moreover, it may well bethat the energy needed for each weld 272 varies from one wire to thenext possibly do to varying oxidation or contamination levels betweenwires and/or terminals. Another possibility for multi-terminal bondingin a single step would be to use different tip sizes or tip dimensionsso that the pressure and location of each is customized. That is, tocustomize or accommodate for any number of wires welded to one terminal54 or any variation of wire gauges (i.e. 26 to 18 gauge). For amulti-wire bond in a single process, each tip could be customized andfeedback could be provided for each individual tip 258 so that theprocess would be completed. Otherwise, if a single tip 258 is used whichgoes from one terminal 54 to the next, pre-programming of the controller75 can anticipate or deal with the variations between each weld 272.

The utilization of ultrasonic welding technology allows for the assemblyof wire harnesses 42 having wire diameters smaller than twenty-two gaugeand ranging at about twenty-six gauge. This results in reduced wireharness 42 bundle size, reduced mass, reduced cost, and furthereliminates wire stripping and the potential of strand breakage or cutsthat stripping produces. Also, connection to ultra-thin wall wire orcable is now possible.

Referring to FIG. 1, with the welding process complete for everyterminal 54 held within the wafers 52 which are held within the pallet56, the conveyor 58 via the controller 75 moves the pallet 56 to thenext station, identified as the wire marker 70.

The Wire Marker:

Referring to FIGS. 1 and 34–37, the conveyor 58 carries the pallet 56,the wafer assemblies 48 and the looped, terminated, wires 46 to the nextstation, identified as the wire marker or marker station 70. The wiremarker 70 is preferably a carbon dioxide laser which bums identifyingmarks into the insulation jacket 178 of the wires 46. This laser markingtechnique allows the adoption of a one color per wire gauge sizeapproach, eliminating the need to have each color wire for eachrespective gauge size.

In the printing or marking process, it is possible to use differentcolor markings for different insulating jacket plastic materials. Forinstance, a light print on a dark jacket 178, or a dark print on a lightjacket, will both give good visibility. The print color is actually theresult of jacket discoloring due to the burning or exposure to intenselight of the wire jacket 178. The color is thus dependent upon not onlythe material and/or additives of the jacket 178, but also the type oflaser. For instance, a jacket material containing titanium dioxide willdiscolor with exposure to the beam of any one of a variety of lasertypes including that of a carbon dioxide laser.

The time to complete the printing process is dependent upon the numberof printed characters and typically takes less than one second to markone wire 46. The laser wire marker 70 allows the coding of each wire 46within the harness 42. The coding can then be converted or provide theinformation necessary to establish when the wire was made, the wirespecification, and its use to assist maintenance.

During operation of the laser wire marker 70, the pallet 56 isorientated side-by-side or adjacent to an elongated wire tray 284 whichcarries a series of laterally extending parallel grooves 286 defined ona top surface 288 of the tray 284. A comb device 290 of the marker 70aligns and places each wire 46 over each respective groove 286. So thatthe wires 46 are placed within the grooves 286 of the tray 284 in atimely manner, each wafer assembly 48 preferably has its own comb device290. The series of comb devices 290 are supported side-by-side and overthe tray 284 by a substantially horizontal support member 291. Thesupport member 291 is suspended from a rigid stationary structure 292 bya pneumatic or air cylinder 293 which is controlled by the controller 75and is constructed and arranged to raise and lower the support member291 and comb devices 290 toward and away from the tray 284.

The comb device 290 has a series of C-shaped members 294 engaged rigidlyto the support member 291. An upper and lower arm 296, 298 arecantilevered and project away from the support member 291. The upper arm296 carries a substantially vertical threaded hole 300 which receives abolt or pin 302 which projects downward beyond the threaded hole 300 andinto a non-threaded hole or round guide-way 304 carried by the lower arm298. A hollow rod 306 is disposed slideably within the round guide-way304 and concentrically receives the lower end of the pin 302. The rod306 has an upward facing annular surface 308 which is in contact with anend of a vertically orientated coiled spring 307 which is disposedconcentrically about the pin 302 and between the arms 296, 298. Thespring 307 acts to bias a roller 309 engaged to the bottom end of thehollow rod 306 in an extended position below the lower arm 298.

In operation, the support member 291 and the air cylinder 293 move alongthe stationary structure 292 in a lateral direction of the tray andlongitudinal direction of the wire 46 creating a rolling action of thecomb device 290. A tilt mechanism 326 disposed substantially under thesupport member 291 tilts the pallet 56 toward the receiving tray 284 forinitially aligning and placing the wires 46 into the grooves prior tomarking the wires 46 by the laser 328. A series of spring loaded pins orfins 324, project downward from the support member 291, orienting thewires 46 to the respective grooves of the tray. The roller 309 issubsequently biased against the wire 46 by the resilient force of thespring 307 compressed between the annular surface 308 and the upper arm296. The downward bearing force of the spring loaded roller 309 causesthe wire to laterally fall snugly into the groove of the tray formarking by the laser. The springs 307 bias the rollers 309 in a downwarddirection creating a vertical displacement variance which allows for arange of different gauged wires 46.

Referring to FIG. 1, once the wires 46 are marked, the conveyor 58advances the loaded pallet 56 to the wire harness station 72. The waferassemblies 48 and welded wires 46 are then removed from the pallet 56 atthe wire harness station 72 and the empty pallets 56 are placed in thesecond pallet station 74 for reuse and possible reconfiguration. Theautomation process of the wire harness 42 is thus complete and the waferassemblies 48 are then manually loaded into their respective connectorhousings 50 to complete assembly of the connectors 44 and wire harness42.

Additional Features of Wafer

Many features and attributes of the wafer 52 have been described as theyrelate and are required in the overall automatic manufacturing processof the wire harness 42. However, certain attributes previously discussedand elements not yet discussed of the wafer 52 are multi-functional andprovide features which are advantageous to the product itself, separatefrom the manufacturing process.

For instance, referring again to FIGS. 3, 5–9, and 19–20, during theinjection molding process of the wafer 52, the wafer rib 100 provides aflow path for the melted plastic and later adds rigidity to thesolidified wafer 52. Moreover, during final assembly of the electricalconnector 44, the rib 100 of one of the stacking wafer assemblies 48projects snugly into a lateral clearance 311 of the adjacent stackingwafer assembly 48. When the wafers are stacked, the rib 100 of one wafer52 bears down upon all of the ledges 176 of the next adjacent wafer 52adding strength to the lock feature 160. Moreover, when the wafers arestacked, a front surface 310 of the rib 100 bears against a rear edge orsurface 312 of the plate 140 of the tuning-fork portion 136 of theterminal 54, adding yet a third locking feature 314 which prevents theterminals 54 from moving backwards within the cavities 114 duringconnection with a mating connector, as best shown in FIGS. 18 and 19.

Once the wafer assemblies 48 are stacked to one another, they are slidlaterally in the direction of arrow 315 and through a side opening 316carried by the connector housing 50. The housing itself carries aclearance or lateral groove 318 which receives the rib 100 of the bottomwafer assembly 48 indexing the wafers to the housing 50. Although notshown, the housing 50 preferably has a rib disposed opposite the groove318 which is received by the clearance 308 of the top wafer assembly 48.With the wafer assemblies 48 properly indexed within the housing 50, acap 320 of the connector 44 is constructed and arranged to slidelongitudinally of the wafer assemblies 48 and in the direction of arrow321 which is disposed substantially perpendicular to arrow 315. The cap320 slides upon a rail type interface with the housing 50 until the capsnap locks to the housing 50, thus sealing off the side opening 316 andsecuring the wafer assemblies 48 within the connector housing 50.

The wafers 52 can also be designed slightly different from one-anotherto assure proper stacking order. For instance, the plastic of the wafercan be of various colors and/or they may include stacking order indexfeatures such as a small tab on one wafer which fits into a hole of theadjacent wafer. The tabs and holes may vary in location depending uponthe stacking order.

The wafer assembly design need not be limited to wire harnesses, but canbe utilized in a wide variety of applications. For instance, the waferscan be utilized as fuse box receptacles. They can be stacked on top ofone-another and side-by-side to form multiple rows and columns. Theterminals 54 may then mate to dual bladed fuses which extend betweenwafers.

Additional Features of Terminal

Referring to FIG. 16, many features and attributes of the terminal 54have been described as they relate and are required in the overallautomatic manufacturing process of the wire harness 42. However, certainattributes previously discussed and elements not yet discussed of theterminal 54 are multi-functional and provide features which areadvantageous to the product itself, independent of the manufacturingprocess.

For instance, the thick stock tuning fork portion 136 of the terminal 54has lower bulk resistance than thinner stock “formed” terminals commonlyused. The “blank” style contact of the flats or tuning fork portion 136is more accurate and stable than “formed” contacts commonly used,resulting in a more consistent contact and pin terminal engagementforce. The thin stock of the crimping portion 132 provides for maximumrange of wire gauge capability. During manufacturing of the terminal 54,the short progression of the terminal 54 allows multiple terminals to beformed in a single die stroke, and the carrier-through-terminal bodyconfiguration with intermittent blanks 125 reduces material usage andcost. The open contact design of the base portion 126 facilitatespost-stamp plating.

While the forms of the invention herein disclosed constitute presentlypreferred embodiments, many others are possible. It is not limitedherein to mention all the possible equivalent forms or ramifications ofthe invention. It is understood that the terms used herein are merelydescriptive rather than limiting and that various changes may be madewithout departing from the spirit or scope of the invention.

1. A wire harness manufacturing machine for attaching a terminal to awire having a surrounding insulation jacket comprising: a wire loaderstation constructed and arranged to measure and cut a wire having asurrounding insulation jacket and crimp a terminal to the insulationjacket of the wire during a loading process; an ultrasonic welderstation having a tip arranged for direct contact with the insulationjacket of the wire and an opposing anvil arranged for direct contactwith the terminal during a welding process, so that the terminal and theinsulation jacket of the wire can be disposed directly between the tipand the anvil and in direct contact with each other; the tip and anvilbeing constructed and arranged to compress the wire directly to theterminal while galling a conductive core of the wire to the terminal,the wire loader station and the ultrasonic welder station being inconsecutive order, wherein the wire loader station has a pair ofopposing grippers for releasably gripping the insulation jacket, and aplunger that slides between the opposing grippers, the plunger having alongitudinal rib or elongated peak arranged to create a longitudinalimprint or split in the insulation jacket at a weld segment, and theterminal and the tip of the ultrasonic welder station are constructedand arranged to be in compressive direct contact with the insulationjacket at a weld segment of the insulator jacket so that the insulationjacket flows away from the conductive core of the wire at the weldsegment to form a displacement mass during an ultrasonic weldingprocess.
 2. The wire harness manufacturing machine set forth in claim 1comprising: the anvil having an upward facing work surface for directlycontacting a bottom surface of the terminal; and the ultrasonic welderstation having a pair of ears projecting between the tip and the anvil,wherein the work surface is disposed substantially between the pair ofears to trap the conductive core between the tip and the terminal duringthe welding process.
 3. The wire harness manufacturing machine set forthin claim 1 wherein the plunger has a concave crimp portion for engaginga crimp wing of the terminal.
 4. A wire harness manufacturing machine incombination with a terminal having a flat wingless base portion to awire having a surrounding insulation jacket comprising: a wire loaderstation constructed and arranged to measure, cut, place and crimp a wireto a terminal of a wire harness during a loading process; an ultrasonicwelder station having a tip arranged for direct contact with the wireand an opposing anvil arranged for direct contact with the terminalduring a welding process, so that the terminal and the wire can bedisposed directly between the tip and the anvil and in direct contactwith each other; and wherein the tip and anvil are constructed andarranged to compress the wire directly to the terminal while galling aconductive core of the wire to the terminal, the anvil having an upwardfacing work surface for directly contacting the flat wingless baseportion of the terminal; the tip having a downward facing work surfacefor directly contacting an insulation jacket of the wire duringinitiation of a welding process; and the ultrasonic welder stationhaving props engaged to and for supporting the tip and the anvilrespectively, and a pair of ears engaged to one of the props, whereinthe pair of ears extend upward on either side of the terminal fortrapping the wire laterally between the tip and the terminal during thewelding process; the pair of ears being spaced apart from each other ata distance slightly greater than the width of the flat wingless baseportion of the terminal.
 5. The wire harness manufacturing machine setforth in claim 4 wherein the tip has a width almost as great as thedistance between the pair of ears.
 6. The wire harness manufacturingmachine set forth in claim 4 wherein the work surface of the tip issmooth and the work surface of the anvil is knurled.
 7. The wire harnessmanufacturing machine set forth in claim 4 wherein the pair of ears areconstructed and arranged to be detachable from the prop.
 8. The wireharness manufacturing machine set forth in claim 7 wherein the pair ofears are made of a softer metal than the anvil.
 9. The wire harnessmanufacturing machine set forth in claim 8 wherein the tip and the anvilare made of hardened steel.
 10. The wire harness manufacturing machineset forth in claim 8 wherein the anvil, the pair of ears, and the tipare coated with titanium nitride.
 11. The wire harness manufacturingmachine set forth in claim 4 wherein the pair of ears are engaged to theone of the props supporting the anvil.